Safety, Performance & Innovation in Oil&Gas Rotating Machines

Transcription

1 ABB PA OGP A&ES & Politecnico di Milano DEI November 28th, 2012 mct Tecnologie per il petrolchimico Safety, Performance & Innovation in Oil&Gas Rotating Machines

2 Market Analysis Compressors and Pumps About 2000 new compressor and 5000 new pumps installed every year for Oil, Gas & Petrolchemical market (from 2010 data) 30% of the market are motor & VSD driven New LNG plants & new pipelines (Asia, Brazil, Russia and North America) Compressing and pumping are expensive processes Main source of inefficiency: Old machinery Sub-optimal control schemes Bad tuning & maintenance December 4, 2012 Slide 2

3 The Power of Integration Process and Power Automation together December 4, 2012 Slide 3

4 The Power of Integration Process and Power Automation together December 4, 2012 Slide 4

5 The Power of Integration Process and Power Automation together December 4, 2012 Slide 5

6 Traditional control solution for rotating equipments A fragmented architecture December 4, 2012 Slide 6

7 Lesson Learnt From Traditional Solution. Safety & Protections Process Automation Machine Control December 4, 2012 Slide 7 Electrical Automation

8 ABB Inc. December 4, 2012 Slide 8

9 DEIC Drive & driven equipment integrated control system The integrated solution providing all the functionalities required for the driving and driven rotating machine Features Complete libraries of control and protection funtions Supervision & monitoring on the assets Open & modular structure Easy integration with other ABB or third party systems Small footprint Reliable and safe hardware certified by TÜV Rheinland Software designed according to IEC61131 standard December 4, 2012 Slide 9

10 DEIC Drive & driven equipment integrated control system The integrated solution providing all the functionalities required for the driving and driven rotating machine Features Complete libraries of control and protection funtions Supervision & monitoring on the assets Open & modular structure Easy integration with other ABB or third party systems Small footprint Reliable and safe hardware certified by TÜV Rheinland Software designed according to IEC61131 standard December 4, 2012 Slide 10

11 DEIC Drive & driven equipment integrated control system Compact version, fully functional, no PC required Complete DCS solution, granting best performance and high safety level Designed to respond to highest and strictest safety requirements, up to SIL3 level December 4, 2012 Slide 11

12 ENI Norge Goliat FPSO Reservoir: Oil & Gas Start production: late 2013 Production: more than oil-drums per day, 3.9 million cubic meter gas per day and store oil drums Client / Country: ENI Norge Duration: Scope of Work: Feed, Electrification, Instrumentation, Control, Advanced Solution, Telecommunication ENI Norge requirement: Minimize the number of interfaces for Electrical, Instrumentation, Control and Telecommunication systems Support during FEED Service Support December 4, 2012 Slide 12

13 GOLIAT Automation Architecture Safety & Protections Process Automation Machine Control Electrical Automation December 4, 2012 Slide 13

14 GOLIAT Automation Architecture Safety & Protections Process Automation Machine Control Electrical Automation December 4, 2012 Slide 14

15 Not just Integration The other areas of Innovation Main areas of innovation: Anti-Surge & Drive-assisted Anti- Surge Control Advanced Load Sharing Performance Monitoring System

16 Compressor instabilities Surge Gas compressors are unstable in certain operating conditions Unstable operation can be easily depicted in Surge is the most dangerous instability, related to low flow, high discharge and/or low suction pressures Volumetric flow [m3/h] Time [s] Surge s pressure and flow oscillations cause high compressor s blades thermal and mechanical stress The stress can be intense and cause blades breaking Maximum efficiency stands very close to surge limit

17 Compressor instabilities Anti Surge Control Pressure Pitch Pressure drop Flow drop

18 Antisurge control Includes all standard anti-surge control functionality: Control-line control Surge protection by ensuring 100% valve signal before reaching the surge line Suction/discharge pressure control Gain-scheduling and valve linearization functionality Fast control cycle time (10ms) Provides a fully open and integrated antisurge control system: Reduces installation, commissioning, training, and maintenance costs Providing the operators with the same look and feel of the other control blocks December 4, 2012 Slide 18

19 Anti surge control The contribute of VSD Variable Speed Drives (VSD) as driver of compressors and pumps is the new growing trend This solution enhances availability and energy efficiency of the system The only solution for subsea applications VSD have a response time of few milliseconds to a step speed reference change Gas turbines have a response time of several seconds This rapidity can pave the way to new surge protection schemes

20 Anti surge control The contribute of VSD Standard Anti-Surge Control suffers the slow speed of the anti-surge valve Surge can take few fractions of seconds to appear. VSD are significantly faster than the ASV and can help the compressor to stay safe while the ASV opens. Coordinated control between VSD and ASV is a challenge in compressor protection systems

21 Advanced Load Sharing What is Load Sharing Optimization Case Study: Two Similar Compressors operating in parallel PT FT PT FT Initial operating point Less efficient (Same Speed / Flow) Optimized operating point Energy Saving (Different Speed / Flow) Same Head High Efficiency

22 Advanced Load Sharing What is Load Sharing Optimization Control Optimization Identification and learning

23 Advanced Load Sharing A new approach DEIC Advanced Load Sharing Currently the load balance between parallel compressors is computed by: Desired Pressures and Flow Process Control Same flow Same distance from surge Advanced load sharing is based on optimization of machines performance taking into account: Performance maps Compressors aging Corrected References FT Field Information Field information The optimization parameters are adapted as the system changes by using learning algorithms. PT PT FT

24 Hour 09:02:00 09:04:10 09:06:20 09:08:30 09:10:40 09:12:50 09:15:00 09:17:10 09:19:20 09:21:30 09:23:40 09:25:50 09:28:00 09:30:10 09:32:20 09:34:30 09:36:40 09:38:50 09:41:00 09:43:10 09:45:20 09:47:30 09:49:40 09:51:50 09:54:00 09:56:10 09:58:20 Advanced Load Sharing Pilot project The advanced load sharing is being tested in a pilot site in a gas pumping station of the TransMed pipeline network The commissioning of the system has started in October 2012 After the commissioning of the system, the fuel gas consumption of the compression station has reduced by 3% The estimated fuel gas saving is of 1,5 million cubic meters per year TOTAL TURBOCOMPRESSOR SHAFT POWER [MW] ALS Off ALS On ALS Off 6-5% and the best has yet to come!!!

25 Performance monitoring Expected Performance Actual Performance The Performance Monitoring System provides continuous monitoring of the status of rotating equipment (Compressors, Pumps, Turbines,..) The actual status, measured from the field and the expected status, defined by a model of the rotating machine A vibration analyzer (Analyst) monitors the status of the bearings and of the shaft supported by This tool provides a powerful help for: Machine online status monitoring Predictive maintenance Fault diagnosis

26 December 4, 2012 Slide 26